YAMAHA G9 AG GOLF CART Parts Manual Catalog

YAMAHA SERVICE MANUAL L1T-19616-G9 -93 G9-AJ/EJ G9-AG/AH G9-EG/EH1 G9-EH2 G2-A1E .

NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's educa- tion into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha machine have abasic understanding of the mechanical pre- cepts and procedures inherent to machine repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit for use and unsafe. Yamaha Motor Company Ltd. is continually striving to further improve all models manu- factured by Yamaha. Modifications and sig- nificant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual. SERVICE DEPT LEISURE VEHICLES & POWER PRODUCTS OPERATIONS YAMAHA MOTOR CO., LTD HOW TO USE THIS MANUAL Particularly important information is distin- guished in this manual by the following nota- tions: A WARNING Failure tofollowWARNING instructionscould resultin severe injury or death tothe machine operator, a bystander, or a person inspecting or repairing the machine. AN IMPORTANT indicates special precau- tions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer.

ranee g num disulfide oil aring grease ht lithium-soap base grease num disulfide grease bond 5· ation tion and adjustment ols @ to @ in the exploded grade of lubricant and loca- n point. gent (LOCTITE"') I ols CD to ®> are designed as dicate the chapter's number ols @ to @ are used to iden- tions appearing in the text. D SYMBOLS illustration) CD @ ILLUSTRATE I&F~I~I ISPECI cr-I (Refer to the Illustrated symb ® ® thumb tabs to in 1~8rllNl and content. ENG .1111,,11 CD General inform .. @ Specifications ® Periodic inspec ® ® @Engine ® Cooling system ICOOLI XI ICARBI.I ® Carburetion (j) Power train ® Chassis (j) ® ® Electrical @Troubleshootin Ip<f~RI~1 ICHASI~I ® @ /ELECI_I IJ~~61 ? I @ ~ @I~ III ustrated sym b tify the specifica ® Filling fluid @ Lubricant @ Special tool @ ~ @ ~ @ Tightening @Wear limit, clea @ Engine speed @Q,V,A @ ~ @ l0l Illustrated symb @ [ij] @ diagram indicate tion of lubricatio , @Apply locking a B @ Apply engine oi ® Apply gear oil @ ® ® ® Apply molybde 1 1 1 @ Apply wheel be @Apply lightweig m m a @Apply molybde ® Apply Yamaha @ @ ® ® C8_, .. , CM_, ~

INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT POWER TRAIN ~ GEN INFO ow-- SPEC ~ INSP ADJ ~ POWR TR •

CONTENTS CHAPTER 1 GENERAL INFORMATION CAR IDENTIFICATION t -t FRAME SERIAL NUMBER (Primary I.D.) , -, CHAPTER 2 SPECIFICATIONS TRANSMISSION ,- , CHAPTER 3 PERIODIC INSPECTION AND AJUSTMENT INTRODUCTION 3-' PERIODIC MAINTENANCE TABLE 3-' TRANSMISSION OIL LEVEL MEASUREMENT 3·2 TRANSMISSION OIL REPLACEMENT 3-2 CHAPTER 6 POWER TRAIN TRANSMISSION 6-' REMOVA L 6-2 INSPECTION 6-5 ASSEMBLy 6·5

G9-E CAR IDENTIFICATION/TRANSMISSION I ~EF~I~I GENERAL INFORMATION CAR IDENTIFICATION FRAME SERIAL NUMBER (Primary I.D) The frame serial number G) is located on the rectangular pipe under the operator's seat. Starting Serial Number: G9-E JH7-100311-100410 JH7-101111 - and later ill _________ ISPECI rr I SPECIFICATIONS TRANSMISSION Model G9-E Differential/Reduction Gear: G.E. TRACTION MOTOR Reduction Gear Ratio/Gear Type (1:11.965l/Helical Differential Type Bevel gear Oil Type/Capacity SAE 90 Gear oil/300 cc (0.26 Imp qt, 0.32 US qt) 1-'

INTRODUCTION/PERIODIC MAINTENANCE TABLE I ~8f IIIl!aI PERIODIC INSPECTION AND ADJUSTMENT INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, iffollowed, will ensure more reliable vehicle operation and a longer service life. This information applies to vehicles already in service as well as new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. PERIODIC MAINTENANCE TABLE Use this table to determine maintenance by the number of rounds (hours) or the period whichever comes first. TRANSMISSION For G9-E 0 Checking or Adjusting • LUbricating or Replacing EVERY Item Remarks Pre- 120Rounds 125rds 250rds 500rds 1000rds 10hours 60hrs 130hrs 250hrs 500hrs Operation (1month) (6mns) (1year) (2yrs) (4yrs) Trans- Check for operation and installation of 0 mission speed limiter. case Check for operation of forward-reverse shifting. 0 Check for damage of shifting cable, 0 • replace. Check gearbox oil level and leakage. 0 Replace gearbox oil. Oil quantity: • 300 co (0.26 Imp qt, 0.32 US qt) Oil type: SAE 90 gear oil 3-1

Transmission oil level inspection steps: • Place the vehicle on a level surface. • Remove the oil level plug @. NOTE: Place an oil pan under the transmission case cover. • Add sufficient oil until it begins to flow out from the level plug hole@. ~ Recommended Oil: SAE 90 gear oil Ifll_Itli Do not allow foreign material to enter the transmission case cover. • Allow excess oil to flow out until it stops. • Install the oil level plug. , Oil Level Plug: For G9-E 44 Nm (4.4 m • kg. 32 ft • Ib) TRANSMISSION OIL LEVEL MEASUREMENT/ IINSP I~I TRANSMISSION OIL REPLACEMENT . ADJ .. ~. !~ ~ V::= " - - --- -- \ . TRANSMISSION OIL LEVEL o 0 0 ~\ rt 1 MEASUREMENT ~, t,,: :~ 1.Remove the rear cover (D and rear cowl ®. -- . ----=- 2.Check: l--~==!::::::::::::::::::;::::;:::::::.::::~=::"::::-~ • 0 il level ~~ OIII~,'I~~ Add sufficient oll TRANSMISSION OIL REPLACEMENT 1.Place the vehicle on a level area. 2. Place an oil pan under the transmission case. 3-2 I

TRANSMISSION OIL REPLACEMENT I ~8f IPJaI 3.Loosen: • Transmission case bolt 4.Remove: • Transmission case cover Drain the transmission oil. NOTE: Separate the transmission case cover from the case assy using a gasket scraper CD. 5.lnstall: • Transmission case cover (See page 6-5) 6.Loosen: • Oil level plug 7.Fill: • Transmission case from oil level plug Refer to "TRANSMISSION OIL LEVEL MEASUREMENT" section. Recommended Oil: SAE 90 gear oil Oil Ouantity: 300 cc 10.26 Imp qt, 0.32 US qt) cCAUTION: Do not allow foreign material to enter the transmission case. 8.Tighten: • Oil level plug 3-3

TRANSMISSION Ip<f¥rR~1 POWER TRAIN TRANSMISSION Q) Circlip @ Bearing ® O-ring (jj) O-ring @ Bearing @ Counter gear ass'y G) Input shaft © Bearing ® Bearing ® Ring gear ® Case ass'y @ Differential ass'y (j) Blind plug @ Bearing holder ® Cirelip @ Transmission case cover ® O-ring @ Hexagon nut @) Rear axle hub ® Cirelip @ Bearing @ Cirelip ®I Oil seal @ Rear axle shaft A TRANSMISSION OIL: 55 Nm (5.5 m· kg. 40 ft· Ib) 97 Nm (9.7 m• kg, 70ft· Ib) Reeeommended oil : B SAE 90 gear oil I [;111 REDUCTION RATIO: (1:11.965) D Oil quantity: C 300 em' (0.26 Imp qt. 0.32 US qt) 32 Nm (3.2 m· kg, 23 ft· Ib) 44 Nm (4.4 m • kg, 32 ft· Ib) 55 Nm (5.5 m· kg, 40 ft • Ib) 6-1

YAMAHA G9 AG GOLF CART Parts Manual Catalog

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